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Electromobility with INSYS icom

Communication technology for the E-mobility charging infrastructure

Charging solutions for the mobility turnaround

The energy transition is playing an important role on the way to climate neutrality. Road traffic will contribute its share by replacing combustion engines with electric drive systems based on green electricity. In addition to drive and battery technology, charging options are the key success factor here. Numerous, reliable and flexible charging points are therefore essential to make e-mobility viable and to provide the future infrastructure for road traffic.

This is by no means relevant only to energy suppliers, grid providers and automobile companies. Every company with interfaces to E-mobility needs to expect changes and opportunities, and to actively shape them: it is entirely possible that in your environment, too, there will be a need for action in the areas of charging station solutions, charging network operation or fleet management.

Charging infrastructure in practice

The following interactive illustration shows the individual processes of a charging operation:

According to ISO15118-3, routers such as the Powerline Green PHY™ from INSYS icom can securely guarantee the data communication between charging point and vehicle, thus ensuring the optimal charging process.

Reservation and arrival

You can use an app to search for a charging point, reserve it and activate it after you arrive. Alternatively, charging cards in the credit card format are used, and payment via a credit card terminal is now required by law.

In electromobility, charging points can already be reserved via an app when approaching them.

Attaching the charging cable

The vehicle’s charging socket is connected to the charging point via the appropriate charging cable – in Europe these are so-called Type 2 or CSS plugs. As a charging customer you need to carry the appropriate cable with you.

The communication between the charging station and the electric vehicle is handled by the Powerline Green PHY from INSYS icom.

Starting the charging process

If you have booked in advance, the charging process often starts automatically. In individual cases the start must be confirmed at the charging station or in your app.

INSYS icom's Powerline GP (PLC) ensures the automatic charging process with prior booking via the app.

The charging process

Depending on the capacity of the charging point, the process can take up to several hours. Unlike with petrol, vehicles are often not fully charged. Please note: after a grace period following the completion of a full charge, many providers charge extra if you don’t clear the charging station for an extended period of time.

In electromobility, the charging process at a charging pole can last for different periods of time. In addition, it is not common in electromobility to always charge completely.

Completion and billing

During the charging process, the plugs on the vehicle and the column can’t simply be removed. You have to terminate the charging process by authorising the payment via your charging card or the smartphone app in order to be able to disconnect the cable. The charging station or your app will confirm the amount of electricity used, which will be charged to you via a billing system. Terms and payment arrangements differ depending on the provider. Legislation currently stipulates that charging stations must also support credit card payments in the future.

After the charging process has been completed, the communication between the charging station and the electric vehicle must be ensured to enable smooth billing. INSYS icom realises this with its powerful routers for the industry.

Data communication

For vehicle communication, Powerline according to ISO15118-3 is used in order to also use the charging connection as a data connection. In addition, there is the standard for the correct selection of charging modes according to IEC 61851. Furthermore, it must be taken into account that load control – in particular throttling or disconnection – may have to be controllable by the energy suppliers in the future.

The Powerline Green PHY™ of INSYS icom controls the data communication according to ISO15118-3. In addition, the selection of the charging modes is also controlled according to IEC 61851.

Security

Technically complex protocols are used in the communication between the charging point and the vehicle. Solutions are also used in the data exchange between the charging point and the respective billing systems to ensure security for users and providers: sensors for environmental conditions, protection against tampering and vandalism, encryption for charging statuses and billing, etc.

Security is of particular importance in the communication from the charging point to the electric vehicle. This is ensured by routers from INSYS icom with the highest priority on IT security.

The basics of charging solutions

The highest availability of charging points is essential for the mobility transition. The required data communication between the charging stations is implemented with Powerline Green PHY™ from INSYS icom.

High availability

If you have to charge, you have to charge. Just as petrol pumps at a filling station very rarely fail to work, the availability of charging stations should always be high.

IT security plays an immense role in data communication at charging points. Routers & gateways are certified by TeleTrust and therefore have a high level of IT security.

Secure communication

Whether it’s reservation, release, charging or billing: the entire process must be consistently protected against manipulation or errors. This is essential for providers and users.

Intelligent data communication with the Powerline Green PHY™ from INSYS icom ensures trouble-free operation between charging point and electric vehicle.

Trouble-free operation

The individual process steps between reservation, charging and billing must be transparent and trouble-free.

Typical requirements and approaches for charging solutions

With INSYS icom products, manufacturers of charging columns of AC and DC charging points benefit from reliable data communication with IT security, remote access options and Powerline according to ISO15118-3.

You provide charging stations as a complete technical solution that can be used in private or public spaces. AC-based solutions deliver charging capacities of up to 22 kW, while DC solutions with direct current enable so-called “fast charging stations”. Unlike the wallbox for the home, public charging stations are subject to strict requirements for functional safety and IT security in order to comply with applicable standards and robustness requirements.

We support charging station manufacturers with reliable internet communication for the charging station (versatile router technology and mobile radio), remote access options and IT security, especially for operation and billing. In addition, we provide know-how, advice and solutions in data communication between the vehicle and the charging station (powerline as per ISO15118-3).

With redundancy, monitoring and remote access, INSYS icom routers convince the operators of charging networks, where functionality and reliability are in the foreground in the overall operation of many charging points.

or you reliability, high availability, functionality and also future-proofing through updates and upgrades are at the top of the priority list, because as a provider you are responsible for the overall operation of many charging stations.

Data communication is therefore crucial for charging network operators, because the infrastructure for charging stations differs from place to place. Monitoring and, if necessary, redundant communication channels via mobile radio communication are important here, so that operation, maintenance or fault correction and ultimately billing all work properly.

A wide variety of flexible solutions are required in fleet management, where e-mobility is regarded as an entire service that is to supply entire vehicle fleets. Routers from INSYS icom convince here with the flexible solution approaches for individual solutions.

For you, e-mobility is an overall service. You offer charging solutions in a purchase or rental model and for a wide variety of purposes, often managing groups of vehicles or entire fleets. This involves flexible solutions such as equipping charging stations in an underground car park, where mobile communication and load management are key issues. Cars are not necessarily the target area. E-buses or other types of vehicles such as delivery vehicles also fall into this category, where intensive continuous operation has to be guaranteed and automated as far as possible.

Solutions and products from INSYS icom

In order to make e-mobility practical, INSYS icom offers a powerful combination of solutions expertise, products and technology:

Charging communication: between vehicle and charging station

  • Powerline Green PHY™ gateway from our own development and production as the core technical element for data communication with the vehicle in accordance with ISO 15118-3 and DIN SPEC 7012, including plug & play capability.
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In Smart Charging, the charging station (EVSE) communicates with the electric vehicle (PEV) via the charging cable using the HomePlug Green PHYTM powerline standard according to ISO15118-3. In this process, the data stream is modulated onto the pilot conductor of the charging cable.

Internet communication: router portfolio incl. edge computing, device management and mobile radio communication options

  • Router portfolio with flexible and redundant communication paths such as mobile radio or fibre, as well as the icom OS operating system with support for individual software solutions that run on site in the routers of the charging stations as encapsulated container applications (edge computing, e.g. for charging service administration and load management).
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The modular design of the INSYS icom MRX router is not only convincing due to flexible expansion options, extensive routing functions and high IT security, but is also future-proof and ideally suited for individual requirements.
  • SIM solutions for Europe-wide mobile communication – everywhere and reliably.
  • iRM router management for the administration of all charging station routers, including your existing software solutions. Integration into an existing charging station management system and zero-touch provisioning are planned.

Remote maintenance & VPN: designing operational security.

  • Various VPN solutions for the high security requirements of DC charging stations. You can, for example, build up a network based on the OpenVPN standard with the icom Connectivity Suite – VPN. Central management and simple operation ensure central and secure maintenance access to various charging station components.
  • Know-how and solutions for Powerline Green PHY™.
  • Project support for the integration of our hardware and software components up to a complete solution for communication technology that can be rolled out automatically.
  • Expertise in the area of critical infrastructure with customers from the utilities sector.

Consolidation of data communication

  • Design of all Internet communication via a central router, e.g. for the connection of payment systems.
  • Secure remote access or back-end access for the standard components and E-Mobility application processes (e.g. OCPP) of charging stations.

Consulting and project support

  • Consulting for individual projects up to charge controller development (SECC).
  • Know-how and numerous partners for monitoring solutions.
  • Support for the implementation of additional use cases, e.g. for payment systems or other digital services.

This makes INSYS icom a strategic partner when it comes to ensuring smooth and trouble-free overall operation and also designing your own applications in order to develop new operating models.

INSYS icom products can be used in the e-mobility sector to ensure operational security through remote maintenance and VPN. INSYS icom scores points here with its expertise in Pwerline Green PHY™ and various VPN solutions for the highest IT security requirements.
INSYS icom convinces in electromobility with expert knowledge around the terms Powerline Green PHY™, AC and DC charging columns, ISO15118-3, IEC 61851, load management, type 1 and type 2 plugs, as well as combo plugs, wallboxes and superchargers.

Basic technology

Powerline Green PHY™

A hardware communication solution, often in the form of a specialised chip, that enables data communication within power grids. This uses a form of the powerline protocol, which is also known for the extension of IP networks via sockets, accordingly allowing charging points and vehicle systems to communicate for the switching, start and end of the charging process.

AC/DC

AC stands for alternating current. Charging capacity of up to 22 kW is typical. DC means direct current. Much higher charging capacity of 200 kW and more is possible here, but direct current is predominantly found in industrial environments and along motorways. DC charging still dominates in the commercial sector and along motorways.

ISO15118-3

Protocol for data communication between an electric vehicle and a charging station, which supports the Combined Charging System (CCS). Smart charging and plug & charge are envisaged in terms of energy storage, load/charge management in the smart grid and for flexible charging rates.

IEC 61851

This basic standard, which is intended for electrified vehicles, regulates different charging modes on the “physical layer” in order to keep the charging start and the charging session compatible via different high-level protocols (e.g. ISO15118).

Load management

In most cases there isn’t an unlimited amount of charging current available for multiple charging stations. Overall power therefore has to be intelligently managed and distributed, taking into account the number of vehicles to be charged. This is one of the important functions in the field of fleet management or at locations with many charging points.

Type 1 and type 2 plugs and combo plugs

This is the term used for the five-pin (Type 1) and seven-pin (Type 2) physical charging plugs for various electric vehicles. Charging stations and vehicles in Europe mostly use the Type 2 plug. For charging, IEC 61851 is used to manage the charging process. The combo plug supplements Type 2 with additional power contacts and a fast-charging function up to 170 kW.

Wallbox

This refers to a charging station that can be conveniently mounted on a wall. These are often solutions for end users.

Supercharger

The brand name and technology used by the vehicle manufacturer Tesla. These charging stations offer a lot of charging power (> 100 kW), but are based on proprietary technology and are usually not available for use by others.

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We are happy to answer your specific questions and problems.